how do you remove a headlight lens on a 1991 trooper.....just not sure how to start this....does the grill have to come off? and where are the screws that remove the lens? thanks for any help....i'm lost .?!!!

I believe the headlamp is a one piece sealed beam unit. Probably need to disconnect the electrical connector, remove grille and then headlamp assembly. Don't confuse the beam adjustment screws with the attachment screws. http://www.ebay.com/itm/ISUZU-TROOPER-L ... 78&vxp=mtr

Ok, so it must be a halogen. Been too long since I converted to roundeye. I believe with the replaceable halogen bulb, the actual assembly is a single unit though I reckon with an instrument and heat, you could separate the glass from the metal and then reseal it.

The lens is sealed to the metal reflector with what looks like black RTV. You used to be able to buy just the lens to replace it was cracked. Some have had problems with moisture being trapped in side the unit and rusting the reflector. Dealer pricing on a headlight unit are quite high. They take a 9004 bulb.

thanks guys!!! i got one at JC Whitney for 30 bucks out the door shipped to my house.......it looks like there might be a spring holding the lens/reflector assembly in place.....i have to take off the grill (getting around my huge brush guard) and look closer.....still waiting for the part....my bulb is great just the silver metal around the reflector is a rusty pile in the lens (still sealed and unbroke/cracked).....u guys are saving me a headache so thanks again!!

thanks Ian!! i'm interested .....mine is the square lens with two holes for a regular bulb and a small bulb (like a parking light bulb).....it is about 10 inches in width and 6.5 in height ........Shooter thanks always for your help.....it is a semi sealed lens with a hole in the back for two separte bulbs.....the bulbs are fine ...lens reflector is old and flaky!! and the dealership wants 137 bucks without shipping .....thanks you guys!!

ZDSF2 wrote:thanks Ian!! i'm interested .....mine is the square lens with two holes for a regular bulb and a small bulb (like a parking light bulb).....it is about 10 inches in width and 6.5 in height ........Shooter thanks always for your help.....it is a semi sealed lens with a hole in the back for two separte bulbs.....the bulbs are fine ...lens reflector is old and flaky!! and the dealership wants 137 bucks without shipping .....thanks you guys!!

Hey Ian is this light installed with screws and springs?....and do the adjustment screws have to come out too?...I haven't opened up my grill yet (I have a brush guard that might be trouble too! Thanks for the pic...I'm still interested. ~Zack

Zack, the red circles are where the springs mount, at the top of the lamp assembly, they yellow circles indicate where the adjustment screws are one the top/outside and the inside position of the assemblies, if you are looking at the front of the truck. The blue circles are fragile plastic pieces that that allow the lamp to pivot on a ball. These are set into the buckets mounted to the front of the truck and a nut is fastened. When you replace your assemblies, do your best to keep these as one day you may find your lamp sagging due to a broken tab. It has happened to me. Hope this helps.

Once you get this thing opened up, you will see that it is pretty simple. Usually, I will get needle nose pliers and remove the spring, then remove the nut on the pivot ball thingy, then loosen one of the adjustment screws and it should come out easy.

Just a public "Thank You" to Ian "imamonstertruck" not only for providing me with an exc condition used headlight at a reasonable price to replace the rusty one on my 90 Troop., but also the very clear and precise write up on how to actually replace the headlight in ten minutes! Wow that was easy!